Type MHOR 04

Technical Manual
High Speed Pilot Wire Feeder Protection
Publication Reference:

R8042I 2011. ALSTOM, the ALSTOM logo and any alternative version thereof are trademarks and service marks of ALSTOM. The other names mentioned,
registered or not, are the property of their respective companies. The technical and other data contained in this document is provided for information only. Neither
ALSTOM, its officers or employees accept responsibility for, or should be taken as making any representation or warranty (whether express or implied), as to the
accuracy or completeness of such data or the achievement of any projected performance criteria where these are indicated. ALSTOM reserves the right to revise or
change this data at any time without further notice.

R8042I

GRID

Service Manual
type MHOR 04
High Speed Pilot Wire
Feeder Protection

HANDLING OF ELECTRONIC EQUIPMENT

A person's normal movements can easily generate electrostatic potentials of several
thousand volts. Discharge of these voltages into semiconductor devices when handling
electronic circuits can cause serious damage, which often may not be immediately apparent
but the reliability of the circuit will have been reduced.
The electronic circuits of ALSTOM Grid products are completely safe from electrostatic
discharge when housed in the case. Do not expose them to the risk of damage by
withdrawing modules unnecessarily.
Each module incorporates the highest practicable protection for its semiconductor devices.
However, if it becomes necessary to withdraw a module, the following precautions should be
taken to preserve the high reliability and long life for which the equipment has been designed
and manufactured.
1. Before removing a module, ensure that you are at the same electrostatic potential as the

equipment by touching the case.

2. Handle the module by its front-plate, frame, or edges of the printed circuit board. Avoid

touching the electronic components, printed circuit track or connectors.

3. Do not pass the module to any person without first ensuring that you are both at the same

electrostatic potential. Shaking hands achieves equipotential.

4. Place the module on an antistatic surface, or on a conducting surface which is at the

same potential as yourself.

5. Store or transport the module in a conductive bag.

More information on safe working procedures for all electronic equipment can be found in
BS5783 and IEC 60147-0f.
If you are making measurements on the internal electronic circuitry of an equipment in
service, it is preferable that you are earthed to the case with a conductive wrist strap. Wrist
straps should have a resistance to ground between 500k 10m ohms. If a wrist strap is not
available, you should maintain regular contact with the case to prevent the build up of static.
Instrumentation which may be used for making measurements should be earthed to the case
whenever possible.
ALSTOM Grid strongly recommends that detailed investigations on the electronic circuitry, or
modification work, should be carried out in a special handling area such as described in
BS5783 or IEC 60147-0f.

CONTENTS
SAFETY SECTION

1.

DESCRIPTION

2.
2.1
2.2
2.3
2.4
2.5

INSTALLATION
General
Relay mounting
Unpacking
Storage
Site

9
9
9
10
10
10

3.
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.3
3.3.1

COMMISSIONING
Commissioning preliminaries
Inspection
Wiring
Earthing
Insulation
Suggested test equipment
Electrical tests
Tests on pilot wires
Secondary injection tests
Primary injection tests
On load tests
MHOR 04/SOLKOR R Schemes
Onload tests

10
10
10
11
11
11
11
12
12
13
14
14
16
16

4.
4.1
4.2

SETTINGS
Pilot padding resistors
Neutral tap N

18
18
18

5.

MAINTENANCE

18

6.
6.1
6.2
6.3
6.4

PROBLEM ANALYSIS
Removal of the relay from its case
Pilot padding resistor Rpp
CAG element
Spares

18
19
19
19
19

REPAIRS

19

COMMISSIONING TEST RECORD

25

REPAIR FORM

27

7.

SAFETY SECTION
This Safety Section should be read before commencing any work on
the equipment.
Health and safety
The information in the Safety Section of the product documentation is intended to
ensure that products are properly installed and handled in order to maintain them in
a safe condition. It is assumed that everyone who will be associated with the
equipment will be familiar with the contents of the Safety Section.
Explanation of symbols and labels
The meaning of symbols and labels which may be used on the equipment or in the
product documentation, is given below.

Caution: refer to product documentation

Caution: risk of electric shock

Protective/safety *earth terminal

Functional *earth terminal.

Note: this symbol may also be used for a protective/
safety earth terminal if that terminal is part of a
terminal block or sub-assembly eg. power supply.

*Note: The term earth used throughout the product documentation is the direct
equivalent of the North American term ground.

Installing, Commissioning and Servicing

Equipment connections
Personnel undertaking installation, commissioning or servicing work on this
equipment should be aware of the correct working procedures to ensure safety.
The product documentation should be consulted before installing, commissioning or
servicing the equipment.
Terminals exposed during installation, commissioning and maintenance may present
a hazardous voltage unless the equipment is electrically isolated.
If there is unlocked access to the rear of the equipment, care should be taken by all
personnel to avoid electric shock or energy hazards.
Voltage and current connections should be made using insulated crimp terminations
to ensure that terminal block insulation requirements are maintained for safety. To
ensure that wires are correctly terminated, the correct crimp terminal and tool for the
wire size should be used.

Before energising the equipment it must be earthed using the protective earth
terminal, or the appropriate termination of the supply plug in the case of plug
connected equipment. Omitting or disconnecting the equipment earth may cause a
safety hazard.
The recommended minimum earth wire size is 2.5 mm2, unless otherwise stated in
the technical data section of the product documentation.
Before energising the equipment, the following should be checked:
Voltage rating and polarity;
CT circuit rating and integrity of connections;
Protective fuse rating;
Integrity of earth connection (where applicable)
Equipment operating conditions
The equipment should be operated within the specified electrical and environmental
limits.
Current transformer circuits
Do not open the secondary circuit of a live CT since the high voltage produced
may be lethal to personnel and could damage insulation.
External resistors
Where external resistors are fitted to relays, these may present a risk of electric shock
or burns, if touched.
Battery replacement
Where internal batteries are fitted they should be replaced with the recommended
type and be installed with the correct polarity, to avoid possible damage to the
equipment.
Insulation and dielectric strength testing
Insulation testing may leave capacitors charged up to a hazardous voltage. At the
end of each part of the test, the voltage should be gradually reduced to zero, to
discharge capacitors, before the test leads are disconnected.
Insertion of modules and pcb cards
These must not be inserted into or withdrawn from equipment whilst it is energised,
since this may result in damage.
Fibre optic communication
Where fibre optic communication devices are fitted, these should not be viewed
directly. Optical power meters should be used to determine the operation or signal
level of the device.

Older Products
Electrical adjustments
Equipments which require direct physical adjustments to their operating mechanism to
change current or voltage settings, should have the electrical power removed before
making the change, to avoid any risk of electric shock.
Mechanical adjustments
The electrical power to the relay contacts should be removed before checking any
mechanical settings, to avoid any risk of electric shock.
Draw out case relays
Removal of the cover on equipment incorporating electromechanical operating
elements, may expose hazardous live parts such as relay contacts.
Insertion and withdrawal of extender cards
When using an extender card, this should not be inserted or withdrawn from the
equipment whilst it is energised. This is to avoid possible shock or damage hazards.
Hazardous live voltages may be accessible on the extender card.
Insertion and withdrawal of heavy current test plugs
When using a heavy current test plug, CT shorting links must be in place before
insertion or removal, to avoid potentially lethal voltages.

Decommissioning and Disposal

Decommissioning: The auxiliary supply circuit in the relay may include capacitors
across the supply or to earth. To avoid electric shock or energy
hazards, after completely isolating the supplies to the relay
(both poles of any dc supply), the capacitors should be safely
discharged via the external terminals prior to
decommissioning.
Disposal:

It is recommended that incineration and disposal to water

courses is avoided. The product should be disposed of in a
safe manner. Any products containing batteries should have
them removed before disposal, taking precautions to avoid
short circuits. Particular regulations within the country of
operation, may apply to the disposal of lithium batteries.

Technical Specifications
Protective fuse rating
The recommended maximum rating of the external protective fuse for this equipment
is 16A, Red Spot type or equivalent, unless otherwise stated in the technical data
section of the product documentation.
Insulation class: IEC 61010-1: 1990/A2: 1995
Class I
EN 61010-1: 1993/A2: 1995
Class I

This equipment requires a

protective (safety) earth
connection to ensure user
safety.

Installation
Category
(Overvoltage):

IEC 61010-1: 1990/A2: 1995

Category III
EN 61010-1: 1993/A2: 1995
Category III

Distribution level, fixed

installation. Equipment in
this category is qualification
tested at 5kV peak, 1.2/50s,
500, 0.5J, between all supply
circuits and earth and also
between independent circuits.

Environment:

IEC 61010-1: 1990/A2: 1995

Pollution degree 2
EN 61010-1: 1993/A2: 1995
Pollution degree 2

Compliance is demonstrated by
reference to generic safety
standards.

Product safety:

73/23/EEC

Compliance with the European

Commission Low Voltage
Directive.

EN 61010-1: 1993/A2: 1995

EN 60950:
1992/A11: 1997

Compliance is demonstrated
by reference to generic safety
standards.

Section 1. DESCRIPTION
The MHOR 04 relay provides high speed pilot wire feeder protection.
This is a well established type of protection for feeders. It is based on the Merz-Price
circulating current system and is suitable for operation over privately owned two-core
pilots with a relatively high core resistance (up to 1000 ohms loop) and low intercore
insulation level. The majority of plain feeders can be protected using this arrangement
which features a unit protection scheme with no time or current grading problems, even
on ring circuits.
The three line currents are summated to provide a single phase current for comparison
over a pilot circuit. A padding resistor is provided to adjust the pilot loop resistance to a
constant value of 1000 thus ensuring that the setting remain close to the design value
for all pilot circuits.

1000 Rp
on each relay, 2
2

The padding resistance is set to

where Rp is the pilot loop resistance in ohms.

The diodes in the circuit are arranged in such a way that for all external fault conditions
the relay X is connected at the electrical centre of the pilots on one half cycle and the
relay Y is connected at the electrical centre on the other half cycle. This is shown in
Figure 1.
As shown in Figure 1, there is zero voltage developed across the relay coil for one half
cycle and for the other half cycle diode D2 is reverse biased. Hence for external faults
no current flows in the relay coil and the protection remains stable.
For internal faults current will flow into the relay coils on successive half-cycles.
A special test plug, type MMLB 05 is provided with each relay as an aid to
commissioning and testing.

Section 2. INSTALLATION
2.1

General
Protective relays, although generally of robust construction, require careful treatment
prior to installation and a wise selection of site. By observing a few simple rules the
possibility of premature failure is eliminated and a high degree of performance can be
expected.

2.2

Relay mounting
The relays are either dispatched individually or as part of a panel/rack mounted
assembly in cartons specifically designed to protect them from damage.
Relays should be examined immediately they are received to ensure that no damage
has been sustained in transit. If damage due to rough handling is evident, a claim
should be made to the transport company concerned immediately and
ALSTOM Grid should be promptly notified. Relays which are supplied unmounted
and not intended for immediate installation should be returned to their protective
polythene bags.

2.3

Unpacking
Care must be taken when unpacking and installing the relays so that none of the
parts are damaged or their settings altered and must only be handled by skilled
persons.
Relays should be examined for any wedges, clamps, or rubber bands necessary to
secure moving parts to prevent damage during transit and these should be removed
after installation and before commissioning.
Relays which have been removed from their cases should not be left in situations
where they are exposed to dust or damp. This particularly applies to installations
which are being carried out at the same time as construction work.

2.4

Storage
If relays are not installed immediately upon receipt they should be stored in a place
free from dust and moisture in their original cartons and where de-humidifier bags
have been included in the packing they should be retained. The action of the dehumidifier crystals will be impaired if the bag has been exposed to ambient
conditions and may be restored by gently heating the bag for about an hour, prior to
replacing it in the carton.
Dust which collects on a carton may, on subsequent unpacking, find its way into the
relay; in damp conditions the carton and packing may become impregnated with
moisture and the de-humidifying agent will lose its efficiency.
The storage temperature range is 25C to +70C.

2.5

Site
The installation should be clean, dry and reasonably free from dust and excessive
vibration. The site should preferably be well illuminated to facilitate inspection.
An outline diagram is normally supplied showing panel cut-outs and hole centres.
For individually mounted relays these dimensions will also be found in Publication
R6042.
Publication R7012, Parts Catalogue and Assembly Instructions, will be useful when
individual relays are to be assembled as a composite rack or panel mounted
assembly.
Publication R6001 is a leaflet on the modular integrated drawout system of protective
relay.
Publication R6014 is a list of recommended suppliers for the pre-insulated
connectors.

Section 3.

COMMISSIONING

3.1

Commissioning preliminaries

3.1.1

Inspection
Carefully examine the module and case to see that no damage has occurred during
transit. Check that the relay serial number on the module, case and cover are
identical, and that the model number and rating information are correct.
Carefully remove any elastic bands/packing fitted for transportation purposes.
Carefully actuate the armature of the output element with a small screwdriver/probe.

10

Note that immediately after the point where any normally open contacts just make,
there is a small further movement of the armature. This ensures that contact follow
through and wiping action is present. Repeat similarly with normally closed contacts
on armature release.
Check that the flag is free to fall before or just as any normally open contacts touch.
3.1.2

Wiring
Check that the external wiring is correct to the relevant relay diagram or scheme
diagram. The relay diagram number appears inside the case.
Particular attention should be paid to the correct wiring and value of any external
resistors indicated on the wiring diagram/relay rating information.
Note that shorting switches shown on the relay diagram are fitted internally across
the relevant case terminals and close when the module is withdrawn. It is essential
that such switches are fitted across all CT circuits.
If test block type MMLG is provided, the connections should be checked to the
scheme diagram, particularly that the supply connections are to the live side of the
test block (coloured orange) and with terminals allocated with odd numbers (1, 3, 5,
7, etc.). The auxiliary supply voltage to the scheme, if relevant, should be routed via
test block terminals 13 and 15.

3.1.3

Earthing
Ensure that the case earthing connection above the rear terminal block is used to
connect the relay to a local earth bar.

3.1.4

Insulation
The relay and its associated wiring may be insulation tested between:

all electrically isolated circuits

all circuits and earth

An electronic or brushless insulation tester should be used, having a dc voltage not

exceeding 1000V. Accessible terminals of the same circuit should first be strapped
together. Deliberate circuit earthing links, removed for the tests, subsequently must be
replaced.
3.1.5

Suggested test equipment

Insulation tests:
500V dc insulation resistance tester
Secondary injection tests:
2 test plugs

Use 4mm shrouded plugs (not supplied)

2 test plugs
type MMLB 01
1 single finger test plug type MMLB 02
Overcurrent test set

If MMLG test block is fitted

type CFB or CFBA

or alternatively a current supply capable of 4 x rated current (1A or 5A) and having
a source impedance of greater than 50 or greater than 2 for a 1A or 5A relay
respectively.
Two multipurpose instruments (Avometers, etc.)
Ohmmeter, if not included above

11

Additional equipment for primary injection tests

Primary injection current test set, capable of 50% of CT primary rating and typically
3-5kVA output. An ammeter/measuring CT for measurements of up to 50% CT
primary rating.
3.2

Electrical tests
When conducting tests given in this section, please note:
DANGER
DO NOT OPEN CIRCUIT THE SECONDARY CIRCUIT OF A CURRENT
TRANSFORMER SINCE THE HIGH VOLTAGE PRODUCED MAY BE LETHAL
AND COULD DAMAGE INSULATION.
When type MMLG test block facilities are installed, it is important that the sockets in
the type MMLB01 test plug, which correspond to the current transformer secondary
windings, are LINKED BEFORE THE TEST PLUG IS INSERTED INTO THE TEST BLOCK.
Similarly, a MMLB 02 single finger test plug must be terminated with an ammeter
BEFORE IT IS INSERTED to monitor CT secondary currents.
Secondary injection test methods are included below since they provide a ready
reference for simplified future maintenance tests. They do not however, prove true
primary sensitivities unless CT ratios and losses are known. Secondary injection,
primary injection and on-load tests are included below in this order, although CT
ratios and relative winding polarities for each group of CTs may, if desired, be
proven first.

3.2.1

Tests on pilot wires

It should be noted that at all times pilot cables should be treated as potentially of high
voltage. Standard safety precautions and regulations for working on such cables
should be observed when conducting the following tests. Pilot connections for these
tests can be made to terminals 17 and 18 at the rear of the case, as indicated in
Figure 2, with the relays at both ends removed from their cases, and insulated cards
inserted between the shorting contacts in each case. Do not insert insulated cards on
any other terminals other than 17 and 18.

3.2.1.1 Insulation resistance tests

With the pilots isolated from the relay circuits at both ends of the feeder measure the
insulation resistance between both pilot wires and between each pilot wire and
earth. Measurements will depend on pilot length and type, but a figure in excess of
1M at 500V would normally be accepted as satisfactory. Lower insulation results
should be compared with insulation data for the type of cable used.
3.2.1.2 Pilot loop resistance
Short the remote end of the pilot wires together by removing the insulated card from
the remote relay case and measure the pilot loop resistance with an ohmmeter.
Note the reading for future reference.
3.2.1.3 Identification of pilots for relay connections
It is essential for correct relay operation that each pilot is connected to the same
terminal number on both local and remote relay.
With isolated pilots, short the remote end of one pilot to earth. At the local end
measure the resistance of each pilot to earth. The pilot wire giving the lower of the
two readings corresponds to that earthed at the remote end. Connect the pilots to the
relays as indicated in Figure 2.
12

3.2.2

Secondary injection tests

It is essential that the pilot wires are connected correctly and the remote end relay is
de-energised, as would be the case with an isolated feeder.
If, during maintenance tests, it is impracticable to de-energise the line, secondary
injection testing can only be carried out provided the secondaries of both groups of
line end CTs are terminated, and the relay summation transformer input of the remote
end relay left open-circuit. MMLG test block (if fitted) and MMLB 01 test plug simplify
these circuit changes.
However, before this is done, MHOR04 tripping circuits at both ends must be
isolated to prevent maloperation of the circuit breakers. Back-up protection systems
must be relied on during on-load testing.
The following tests assume initial commissioning tests are being carried out on a
de-energised feeder.

3.2.2.1 Adjustment of pilot-padding resistance

The pilot padding resistance of both line-end relays must first be set to ohmic value
given below.
Pilot padding resistance =

1000 pilot loop resistance

2

ohms

The padding resistance is adjusted at the front of the relay by a potentiometer-type

control that is calibrated directly in ohms.
3.2.2.2 Check on open-circuit pilot sensitivity
Temporarily open circuit the pilots and, with N = 3 on plugbridge on frontplate of
relay, inject A-N current (terminals 23-24). Slowly increase the level until the output
relay operates. Note the pick-up current level which should be 0.13A (1A relay) or
0.65A (5A relay), with a tolerance of 10%.
Remove the open circuit from the pilots.
3.2.2.3 Electrical check on correct pilot polarity
With A-N current injection as in 3.2.2.2 above, but with pilots connected, connect
an ac milliammeter in the pilot circuit to monitor the pilot current. Increase the current
until the local relay just operates noting both the injected level and pilot currents:
these should be nominally 0.235A (1.18A, 5A relay) and 8.2mA respectively, but
will increase with high capacitance pilots.
Temporarily reverse the pilot connections and increase the injected A-N current,
repeating the above. The pick up current should be typically 90-95% of the previous
reading, but the pilot current should be higher and in the order of 10mA. These
results confirm that the correct pilot polarities had been selected. Return the pilot
connections to normal.
3.2.2.4 Record of pick-up settings
Note the desired CT neutral tap setting (N = 3 or 5). A table of nominal pick up
currents for each phase to phase and phase to neutral connection is given in Figure
3, together with a guide to expected tolerances.
Inject A to neutral (N=3 or 5) current and note the local end pick up level.

13

With communications to the remote end, gradually increase the level until the remote
end relay operates. This should occur at 1.2-2.4 x the nominal local end pick up
level.
Repeat, recording the local end PU current only, for B to neutral, C to neutral, A B,
B C and C A injection.
3.2.2.5 Secondary injection tests on untested remote end
Section 3.2.2.2 and 3.2.2.4 should be repeated for the remote end relay.
3.2.3

Primary injection tests

DANGER
WHEN CONDUCTING TESTS IN THIS SECTION THE SECONDARY
WINDINGS OF THE CURRENT TRANSFORMERS MUST NOT BE ALLOWED
TO GO OPEN CIRCUIT. ATTENTION SHOULD BE PAID TO THE DANGER
WARNING AT THE START OF SECTION 3.2.

3.2.3.1 Individual CT ratio and wiring check

Connect ammeters in series with case terminal 23 and the CT neutral and apply a
known level of current (say 50-100% of CT rating) through the A phase CT primary
and measure the secondary currents A1 and A2. Both should be equal and
approximate the primary I x CT ratio. Repeat for the B and C phase CTs, measuring
in terminals 25 and 27 respectively.
3.2.3.2 Inter-phase relative polarity test of CTs
Connect ammeters in series with terminal 25 and the CT neutral as in Figure 4.
With the A2 ammeter initially on a high range (2 x the expected CT secondary
current) energise the A and B phase CTs as indicated, with 50-100% CT rated
current. The A1 ammeter reading should approximate the primary current x the CT
rating, but the A2 ammeter should only record a few milliamperes of spill current.
This test proves that both CTs are of the same polarity. Repeat as indicated in Figure
4 for the B-C phases, still measuring currents in 25 and the CT neutral.
Note:

If 2 x the reading of the A1 ammeter is obtained on A2, one of the two CTs
being tested is of reversed polarity. CT wiring should be carefully checked.
Ideally a CT polarity dc flick test should be carried out, as indicated in
Figure 5, which will prove the definite polarity of each CT.

3.2.3.3 Primary pick up sensitivity

Connect the primary injection test set across the A phase CT primary. Monitor the CT
secondary current into relay terminal 23. Increase the injected current until the local
relay operates, and record both primary and secondary pick up levels.
Similarly, repeat the above for the B and C phase CTs monitoring the secondary
current to the relay at terminal 25 and 27 respectively, ensuring the other CTs are
correctly terminated by the relay.
3.2.4

On load tests
DANGER
WHEN CONDUCTING TESTS IN THIS SECTION, THE SECONDARY
WINDINGS OF THE CURRENT TRANSFORMERS MUST NOT BE ALLOWED
TO GO OPEN CIRCUIT. ATTENTION SHOULD BE PAID TO THE DANGER
WARNING AT THE START OF SECTION 3.2.

14

The following tests should be carried out preferably with at least 50% load current
flowing in the feeder and the relay trip circuits at both ends isolated.
3.2.4.1 Check on load current
If MMLG/MMLB test facilities (or equivalent) are available, measure the CT
secondary load current to ensure that it is above a suggested absolute minimum
20%.
3.2.4.2 Stability test
Short circuit B and C phase CT secondaries and isolate them from the relays at both
ends. This simulates an A-N through fault condition and the most sensitive phase
condition for the relays. When these conditions are applied both relays should be in
the stable, unoperated condition.
Measure the circulating pilot current in terminal 17. This should be approximately
44 or 66mA ac for the 50% or 100% load condition respectively and N = 3 setting,
or approximately 40% higher if the N = 5 setting is used.
Similarly, measure the dc current to the CAG relay element using the special test plug
in the socket on the relay frontplate. The current should be nominally zero, but
certainly less than 1.5mA.
Repeat the above tests for B-N, monitoring pilot current and the dc current in the
CAG coil. These currents should be less than those measured for the A-N condition
because of the relays lower sensitivity to this type of fault.
Repeat again for C-N, noting the still lower values of current.
Note:

If relays operate, or tend to operate, with the above tests, it indicates that the
polarity and/or phasing of the CTs are suspect, or that the polarity of the
pilots is incorrect. Reference should be made to section 3.2.2.3 for pilot wire
polarity tests. On no account should they be changed from that determined
to be correct in section 3.2.2.3. If the CT polarities are incorrect, they must
be corrected at the CTs. Reversing the pilots, as can normally be done on
most pilot wire schemes, may indicate correct results but, on MHOR 04
schemes, THIS MUST NEVER BE DONE, as this would result in through fault
instability at typically 2x full load current.

3.2.4.3 On load operational check

Short circuit B and C phase CT secondaries and isolate them from the relays at both
ends. Reverse the A-N CT secondary connections to relay terminals 23 and 24.
This simulates an A-N internal fault condition. Both relays should operate.
Measure the pilot current in terminal 17, as in 3.2.4.2. This should be nominally
zero, and typically less than 5mA ac.
Similarly measure the dc current in the CAG coil using the special test plug.
This should be typically 21-25mA (0.5 - 1.0 x full load current).
Return CTs to normal connection.
3.2.4.4 Three phase stability check
With 3 phase load current supplied to the relays as in normal service, monitor the
circulating pilot current with an ac milliammeter in terminal 17. This should be
typically 15mA for the 50% load condition or 30mA for the full-load condition.
Monitor also the dc current to the CAG relay element by the test socket. The current
should be nominally zero, but definitely less than 1.5mA.
15

3.2.4.5 Trip and alarm circuit functional check

With the dc trip circuit links/fuses replaced, the circuit breaker should be tripped by
actuating the relay. This can be done by carefully actuating the output relay armature
with a suitable probe/screwdriver.
3.3

MHOR 04/SOLKOR R Schemes

It would be normal practice to install a MHOR 04- - - - MHOR 04 protection scheme,
however where the protection at one end of the feeder has been upgraded a MHOR
04 - - - - SOLKOR R scheme may be encountered. In this case the instructions as
detailed in sections 3.2.3.* should be followed, with the exception of sections
3.2.4.* on load tests, which should be replaced with the following instructions
3.3.1.*.

3.3.1

Onload tests
DANGER
WHEN CONDUCTING TESTS IN THIS SECTION, THE SECONDARY
WINDINGS OF THE CURRENT TRANSFORMERS MUST NOT BE ALLOWED
TO GO OPEN CIRCUIT. ATTENTION SHOULD BE PAID TO THE DANGER
WARNING AT THE START OF SECTION 3.2.
The following tests should be carried out with preferably at least 50% load current
flowing in the feeder, and the relay trip circuits isolated at both ends.
If 50% load current cannot be achieved, then minimum load current of 30% (or even
20%) can be accepted, provided the following instructions are followed precisely.

3.3.1.1 Check on load current.

Measure the CT secondary current. If load current is between 20 30% of CT/relay
rated current, the N = 5 tap must be used, on both line ends. If the load current is
above 30% then the N = 3 tap may be used at both ends.
3.3.1.2 Short circuit B and C phase CT secondaries and isolate them from relays at both
ends. This simulates an A-N through fault condition and the most sensitive phase
condition for the relays. When these conditions are applied both relays should be in
the stable, unoperated condition.
Measure the circulating pilot current in terminal 17. This should be approximately 44
or 66mA ac for the 50% or 100% load condition respectively and the N=3 setting,
or approximately 40% higher for the N=5 setting.
Similarly, measure the dc current to the CAG relay element using the special test plug
in the socket on the relay frontplate. The current should be nominally zero, but
certainly less than 1.5mA.
Repeat the above tests for B-N, monitoring pilot current and the dc current in the
CAG coil. The measured currents should be less than those measured for the A-N
condition, because of the lower sensitivity to this type of fault.
Repeat again for the C-N condition, noting the still lower values of current.
Similar tests should be performed for the Solkor R relay, and reference should be
made to the Solkor R service manual for specific instructions.
Note:

If relays operate, or tend to operate, with the above tests, it indicates that the
polarity and/or phasing of the CTs are suspect, or that the polarity of the
pilots is incorrect. Reference should be made to section 3.2.2.3 for pilot wire
polarity tests. On no account should they be changed from that determined
16

to be correct in section 3.2.2.3. If the CT polarities are incorrect, they must

be corrected at the CTs. Reversing the pilots, as can normally be done on
most pilot wire schemes, may indicate correct results but, on MHOR 04
schemes, THIS MUST NEVER BE DONE, as this would result in through fault
instability at typically 2x full load current.
3.3.1.3 On load operation tests
Short circuit B and C phase CT secondaries and isolate them from the relays at both
ends. Reverse the A-N CT secondary connections to relay terminals 23 and 24.
This simulates an internal fault condition. Both relays should operate.
Measure the pilot current in terminal 17, as in section 3.2.4.2. This should be
nominally zero, and typically less than 5mA ac.
Similarly, measure the dc current in the CAG coil using the special test plug.
This should be typically 21-25mA (for the 0.5-1.0 x full load current condition).
Return the CTs to normal conection.
3.3.1.4 Three phase stability check.
With three phase load current supplied to the relays as in normal service, monitor the
circulating pilot current with an ac milliammeter in terminal 17. This should be
typically 15mA for the 50% load condition, or 30mA for the full load condition.
Monitor also the dc current to the CAG relay element at the test socket. The current
should be nominally zero, but may peak at 2.5mA if only 20% load is present.
3.3.1.5 Trip and alarm circuit functional check
With the dc trip circuit links/fuses replaced, the circuit breaker should be tripped by
actuating the relay. This can be done by carefully actuating the output relay armature
with a suitable probe/screwdriver.

17

Section 4. SETTINGS
4.1

Pilot padding resistors

These variable resistors are used to pad the pilot resistance up to a constant
1000 . For example, If the pilot circuit has a total loop resistance of 600 , the pilot
padding resistance at each end of the pilot circuit should be set to

1000 pilot loop resis tan ce

2
4.2

Neutral tap N
The relay settings may be reduced by putting N = 5 as in the table of settings below:
Type of fault

Fault settings % In
N=3

N=5

A-N
B-N
C-N

25
32
42

18
21
25

A-B
B-C
C-A
A-B-C

125
125
62
72

Note that N must be set to the same value at both ends of the pilot circuit.

Section 5. MAINTENANCE
Periodic maintenance is not necessary. However, periodic inspection and test is
recommended.
The relay flag should be examined and checked to ensure that it falls correctly. The
flag reset should be checked for correct operation. Contacts should be examined for
signs of wear or damage, such as pitting.

Section 6. PROBLEM ANALYSIS

It should be noted that any problems that arise are likely to be of a catastrophic
nature and not readily site repairable for the following reasons:
Most components are mounted on a printed circuit board. It is recommended that
faulty boards are replaced as attempts to change components on them will result
in damage to the protective coating.
Should either or both of the large disc metrosils be damaged it is a virtual
certainty that other components will be seriously damaged.
If the CT has been damaged it is likely that much of the relay will have suffered

from the attendant heat/smoke. This leaves the pilot padding resistor and the
CAG measuring element which are more readily repaired or replaced on site
although it is recommended that these too are attended to either by the factory or
an ALSTOM Grid service centre.

18

6.1

Removal of the relay from its case

To remove the relay from its case, loosen the cover nuts and remove the cover.
The relay can now be withdrawn from the case by pulling on the handles.

6.2

Pilot padding resistor Rpp

Connect the probes from a multimeter on the ohms range to the terminals on the
variable resistor Rpp. Rotation of the knob between its limits should produce a
resistance varying from zero to approximately 600. If the variable resistor is found to
be defective it may be replaced, remembering to lift the link between the terminals as
for the original unit. The knob should be refitted to indicate 2.5 when the multimeter
indicates 250. The calibration should be check at 100, 200, 300, 400 and
500 settings. All should be accurate within 5% or 10, whichever is the greater. No
further recalibration is necessary.

6.3

CAG element
If the flag fails to operate correctly it may be adjusted by gently bending the spring
clip to the left of the armature. This should be set so that the flag falls just before the
contacts close. This should not affect relay calibration.
If the coil or contacts are damaged it is strongly advised that the entire relay is
returned for the remedial work to be performed, as the relay would have to be
completely recalibrated in accordance with ALSTOM Grid test specification
reference Z7 MHOR04.

6.4

Spares
When ordering spares the serial number and model number of the relay should be
included with the order.
Repairs
Should the need arise for the equipment to be returned to ALSTOM Grid for repair,
then the form at the back of this manual should be completed and sent with the
equipment together with a copy of any commissioning test results.

19

A
B
C
D1

D1
Rp

x
R1

D2

Operating
coil

R1
v
_

y
R1
D2

Operating
coil

Rp

_
_

(a)

_
v

_
(b)

v
_

_
v

(c)

Point x

Point y

(a) and (b) show the effective circuits during successive half cycles
(c) indicates the voltages across relaying points x and y during one cycle

Figure 1 Behaviour of basic MHOR 04 circuit under external fault conditions when R1=Rp

20

21

26

28

25

27

S2

P2

3
2WBK
BK

RVD1

C.T. shorting links make

before (b) & (c) disconnect
(b)
Short terminals break before (c)
(c)
Long terminals
Note 2 Earthing connections are typical only
Note 3 C.T. connections are typical only

Note 1
(a)

2WBN

2WW

2WR

N 2WP

Case earth
see note 2

28

27

26

25

24

23

2/3 R2

RVD3

R1

D1

RVD4

ZJ0069

6/7

D3

R3

D2

Protected zone

Figure 2 Circuit diagram: MHOR04 high speed pilot wire feeder protection relay

Module terminal block

viewed from rear

24

23

18

17

20

16

15

22

14

13

21

12

11

19

10

Case earth

B
C
Phase rotation

See note 3
P1
A
S1
B

MHOR 04

RL1
4

1
3
5
7

Trip circuit test

and isolation

2
4
6
8

Viewed from front

RVD2

RPP

1
wires

Pilot

28

27

26

25

24

19

Case earth
see note 2

23

MHOR 04

S2

P1
S1

Contact description
M : make
B : break
P2

Actual nominal pick up current

Injected phase

Plugbridge
setting N

Claimed setting
as % of I rated

1A relay

5A relays

A-N

25

0.235

1.18

B-N

32

0.294

1.47

C-N

42

0.392

1.96

A-N

18

0.168

0.84

B-N

21

0.196

0.98

C-N

25

0.235

1.18

A-B

125

1.18

5.88

B-C

125

1.18

5.88

C-A

62

0.588

2.94

A - B - C*

72

0.678

3.39

* Reference only
Note: Site commissioning tolerances
The nominal setting currents given above are for resistive pilots of up to 1000, but
having little intercore capacitance. A commissioning tolerance of +10% should be
allowed. An additional + 25% increase in operating current can be expected if
intercore capacitance approaches 2.5mF.
Figure 3 Relay pick up settings, single-end injection

22

Feeder

C
Primary injection
test set

Temporary 3
short circuit

A1
23
24
MHOR 04

25
26
27
A2

28

Figure 4 Inter-phase relative polarity test of CTts

Low voltage battery

(ve on feeder inside)

Feeder

C
The dc m/ammeter should give a
+ve flick on making SI, and a ve flick
on breaking repeat similarly for other
CTs.

23
24
25

MHOR04

26
27
28

Figure 5 CT polarity dc 'flick, test

23

+
mA

Section 7.

COMMISSIONING TEST RECORD

Relay Serial No ___________________________

Model No __________________________

Station __________________________________

Circuit Ref __________________________

Remote End Details:

Serial No ________________________________

Model No __________________________

Remote Station ___________________________

Neutral Connection:

N=5

N=3

3.2.1.2 Measured pilot loop resistance

_________

3.2.2.1 Pilot padding resistor Rp set to

_________

Local end secondary injection tests:

3.2.2.2 Open circuit pilot A-N pick up ______ A
3.2.2.3 A-N pick up:
Pilots correct

_______________ A

Pilot I

_______________ mA

Pilots reversed

_______________ A

Pilot I

_______________ mA

3.2.2.4 Record of pick up settings:

Nominal pick up as a percentage of rated current
Injected I

A-N

B-N

C-N

A-B

B-C

C-A

N=3

25

32

42

125

125

62

N=5

18

21

25

125

125

62

Actual pick up current (Amps)

A-N

B-N

______

______

______

______

C-N

A-B

B-C

C-A

_____ ______

______

_____

_____ ______

______

_____

Remote end pick up I (A-N only)

_________ A

24

On load tests:
3.2.4.2 Stability test
Phase connection

A-N

B-N

C-N

CT sec. load I (A)

_________

________

_________

Pilot circ. I (mA)

_________

________

_________

CAG spill I (dc mA)

_________

________

_________

3.2.4.3 Operational check

(A-N connection) ________

Circulating pilot I

________________ mA

CAG operating I

________________ dc mA

A-N Sec I at time of test

________________ A

Miscellaneous checks
Check flag operate/reset

_________

Check ct shorting switches

_________

Check contact operation

_________

Remarks:

______________________________________
Commissioning Engineer

_______________________________________
Customer Witness

______________________________________
Date

_______________________________________
Date

25

REPAIR FORM
Please complete this form and return it to Alstom Grid SAS with the equipment to be
repaired. This form may also be used in the case of application queries.
Alstom Grid SAS
St. Leonards Avenue
Stafford
ST17 4LX
England
For :

After Sales Service Department

Customer Ref:

___________________

Model No:

___________________

Alstom Grid
Contract Ref:

___________________

Serial No:

___________________

Date:

___________________

1.

What parameters were in use at the time the fault occurred

AC Volts

___________________

Main VT/Test set

DC Volts

___________________

Battery/Power supply

AC current

___________________

Main CT/Test set

Frequency

___________________

2.

Which type of test was being used

_____________________________________

3.

Were all the external components fitted where required?

(Delete as appropriate)

4.

List the relay settings being used

5.

What did you expect to happen

Yes

No

continued overleaf

PXXX
Product Description

Alstom Grid
- ALSTOM 2011. ALSTOM, the ALSTOM
logo and any alternative version thereof are
trademarks and service marks of ALSTOM.
The other names mentioned, registered or
not, are the property of their respective
companies. The technical and other data
contained in this document is provided for
information only. Neither ALSTOM, its officers
or employees accept responsibility for, or
should be taken as making any representation
or warranty (whether express or implied), as
to the accuracy or completeness of such data
or the achievement of any projected
performance criteria where these are
indicated. ALSTOM reserves the right to
revise or change this data at any time without
further notice.
Alstom Grid Worldwide Contact Centre
www.alstom.com/grid/contactcentre/
Tel: +44 (0) 1785 250 070

www.alstom.com

GRID